US10877188B2 - Composite diffuser plate - Google Patents

Composite diffuser plate Download PDF

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US10877188B2
US10877188B2 US15/564,769 US201615564769A US10877188B2 US 10877188 B2 US10877188 B2 US 10877188B2 US 201615564769 A US201615564769 A US 201615564769A US 10877188 B2 US10877188 B2 US 10877188B2
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diffuser plate
microlenses
microlens array
composite
composite diffuser
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US20180113240A1 (en
Inventor
Junji Watanabe
Masaru Karai
Atsushi Uchida
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Kuraray Co Ltd
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Kuraray Co Ltd
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Assigned to KURARAY CO., LTD. reassignment KURARAY CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WATANABE, JUNJI, UCHIDA, ATSUSHI, KARAI, MASARU
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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/0006—Arrays
    • G02B3/0037—Arrays characterized by the distribution or form of lenses
    • G02B3/0043—Inhomogeneous or irregular arrays, e.g. varying shape, size, height
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
    • G02B5/0231—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures the surface having microprismatic or micropyramidal shape
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/0006—Arrays
    • G02B3/0012—Arrays characterised by the manufacturing method
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0268—Diffusing elements; Afocal elements characterized by the fabrication or manufacturing method
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0273—Diffusing elements; Afocal elements characterized by the use
    • G02B5/0278—Diffusing elements; Afocal elements characterized by the use used in transmission
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133504—Diffusing, scattering, diffracting elements
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B21/00—Projectors or projection-type viewers; Accessories therefor
    • G03B21/54—Accessories
    • G03B21/56—Projection screens
    • G03B21/60—Projection screens characterised by the nature of the surface
    • G03B21/62—Translucent screens

Definitions

  • the present disclosure relates to a composite diffuser plate.
  • a technique has been suggested for applying a single diffuser plate such as a microlens array to a display apparatus.
  • Patent Literature 1 describes an optical design method.
  • this optical design method (a) shapes of microstructures such as microlenses formed on a substrate surface are defined; (b) locations of selected microstructures in an arrangement are specified; (c) an intensity distribution of diffused light is calculated; and (d) steps of (a) to (c) are repeated until a desired diffused light intensity distribution is obtained.
  • Patent Literature 1 further suggests a single diffuser plate for the purpose of reducing luminance unevenness generated by diffraction spots caused by periodicity of microstructures. In this single diffuser plate, at least one parameter defining shapes or locations of the microstructures is randomly distributed in accordance with a predetermined probability density function.
  • Patent Literature 1 shows an angle property of diffused light in the single diffuser having, for example, a lens diameter of 100 ⁇ m, a maximum sag of 10 ⁇ m, and a raised height of ⁇ 2 ⁇ m.
  • the angle of 40° namely, in the vicinity of both ends of a central part that rises upward from both end parts of a top hat-shaped intensity distribution curve, the intensity of luminance is rapidly fluctuated.
  • the luminance is locally uneven.
  • An object of the present disclosure is to provide a composite diffuser plate capable of inhibiting local luminance unevenness.
  • a composite diffuser plate according to the present disclosure includes a first diffuser plate (e.g., a random micro array) and a second diffuser plate (e.g., a mat plate, a uniform micro array) arranged in this order from an incident side.
  • a first diffuser plate e.g., a random micro array
  • a second diffuser plate e.g., a mat plate, a uniform micro array
  • At least one of the first diffuser plate and the second diffuser plate is composed of a random microlens array including a plurality of microlenses.
  • the plurality of microlenses include a plurality of parameters defining a lens shape.
  • At least one of the plurality of parameters is randomly distributed.
  • the random microlens array causes a phase difference to be generated in transmitted light.
  • the first diffuser plate is composed of the random microlens array; diffused light intensity of the first diffuser plate is distributed along a top hat-shaped curve; and a diffusion angle of the first diffuser plate is greater than or equal to a diffusion angle of the second diffuser plate.
  • a top width is a width between a first inflection point and a second inflection point, the first inflection point being at a largest viewing angle from a viewing angle of 0° to a positive maximum value of an absolute value of the viewing angle, and the second inflection point being at a smallest viewing angle from a negative maximum value of the absolute value of the viewing angle to the viewing angle of 0°, a top width of the composite diffuser plate is less than or equal to 1.200 times the top width of the distribution curve of the first diffuser plate.
  • a diffused light intensity distribution of the composite diffuser plate can maintain its top hat-shaped curve in a favorable manner.
  • the second diffuser plate is composed of a mat plate including a micro contoured pattern on its main surface.
  • the second diffuser plate is composed of a uniform microlens array.
  • the uniform microlens array is formed by arranging a plurality of microlenses having substantially the same shape at substantially the same intervals.
  • the random microlens array includes a plate and the plurality of microlenses disposed on a main surface of the plate;
  • the microlens includes a lens part and a raised part that raises the lens part from the plate;
  • each of a plurality of the lens parts of the respective plurality of microlenses has substantially the same length in a convex direction; heights of raise of a plurality of the raised parts of the respective plurality of microlenses are distributed within a predetermined range;
  • the microlens has a convex part maximum height, the convex part maximum height being a sum of a height of the lens part and a height of the raised part; and a maximum height difference ⁇ H [ ⁇ m] of the convex part maximum height of the plurality of microlenses, a refractive index n of a material forming the microlenses, and a wavelength ⁇ [nm] of a light source satisfy 0.2 ⁇ 1000 ⁇ H ⁇ (n ⁇ 1)/ ⁇ .
  • the second diffuser plate further includes a reflection part (e.g., reflection plate); and the reflection part is installed on a main surface opposite to the incident side of the second diffuser plate.
  • a reflection part e.g., reflection plate
  • FIG. 1 is a side view of a composite diffuser plate according to a first embodiment
  • FIG. 2 is a schematic diagram of a main part of the composite diffuser plate according to the first embodiment
  • FIG. 3 is a graph showing an example of an intensity distribution with respect to a viewing angle
  • FIG. 4 is a graph showing a distribution obtained by performing moving average processing on the example of the intensity distribution with respect to the viewing angle
  • FIG. 5 is a graph showing a distribution obtained by taking second derivatives of the intensity distribution with respect to the viewing angle, which has been subjected to the moving averaging processing;
  • FIG. 6 is a graph showing a rate of change in a top width with respect to the viewing angle of an emission side mat plate
  • FIG. 7 is a photograph showing an example of a transmission image of the composite diffuser plate according to the first embodiment
  • FIG. 8 is a graph showing an intensity with respect to the viewing angle of the example of the transmission image of the composite diffuser plate according to the first embodiment
  • FIG. 9 is a photograph showing an example of a transmission image of the composite diffuser plate according to the first embodiment.
  • FIG. 10 is a graph showing an intensity with respect to the viewing angle of the example of the transmission image of the composite diffuser plate according to the first embodiment
  • FIG. 11 is a side view of a composite diffuser plate according to a second embodiment
  • FIG. 12 is a side view of the composite diffuser plate according to the third embodiment.
  • FIG. 13 is a photograph showing an example of a transmission image of the composite diffuser plate according to Example 2-1;
  • FIG. 14 is a graph showing an intensity with respect to the viewing angle of the example of the transmission image of the composite diffuser plate according to Example 2-1;
  • FIG. 15 is a photograph showing an example of a transmission image of a composite diffuser plate according to Example 2-2;
  • FIG. 16 is a graph showing an intensity with respect a the viewing angle of the example of the transmission image of the composite diffuser plate according to Example 2-2;
  • FIG. 17 is a photograph showing an example of a transmission image of a single diffuser plate
  • FIG. 18 is a graph showing an intensity with respect to a viewing angle of the example of the transmission image of the single diffuser plate
  • FIG. 19 is a photograph showing an example of a transmission image of a single diffuser plate
  • FIG. 20 is a graph showing an intensity with respect to a viewing angle of the example of the transmission image of the single diffuser plate
  • FIG. 21 is a photograph showing an example of a transmission image of a composite diffuser plate.
  • FIG. 22 is a graph showing an intensity with respect to a viewing angle of the example of the transmission image of the composite diffuser plate.
  • FIG. 1 is a side view of the composite diffuser plate according to the first embodiment.
  • FIG. 2 is a schematic diagram of a main part of the composite diffuser plate according to the first embodiment.
  • a composite diffuser plate 100 includes a random microlens array 10 and a mat plate 20 . Both the random microlens array 10 and the mat plate 20 are diffuser plates that allow incident light to pass therethrough and that diffuse the transmitted light outward.
  • the composite diffuser plate 100 can be used as a transmissive screen.
  • the random microlens array 10 and the mat plate 20 are arranged in this order from an incident side to an emission side with a predetermined distance therebetween. The distance between the random microlens array 10 and the mat plate 20 may be shorter or longer than a focal length of the microlens 12 .
  • a maximum distance between the random microlens array 10 and the mat plate 20 is preferably a distance that allows all the light passing through the random microlens array 10 to be incident on the mat plate 20 . This is to maintain utilization of the light and to inhibit the property from being deteriorated due to stray light.
  • the composite diffuser plate 100 may be formed by arranging two plates of the random microlens array 10 and the mat plate 20 side by side. Alternatively, the composite diffuser plate 100 may be formed as a unitary molded article.
  • the random microlens array 10 includes a plate 11 and a plurality of microlenses 12 .
  • the plurality of microlenses 12 are provided on a main surface on the emission side of the plate 11 .
  • the plurality of microlenses 12 have a phase difference from one another. This phase difference is expressed by standardizing a difference in optical path lengths of the light transmitted through or reflected by the microlens 12 with a wavelength. This phase difference can be changed by randomly distributing at least one of parameters defining the lenses. Examples of such parameters include a lens height, a lens diameter, a lens curvature, a lens pitch, a lens arrangement, a lens refractive index, and the like.
  • the random microlens array 10 may be referred to as a raised height random microlens array.
  • the random microlens array 10 is the raised height random microlens array, as shown in FIG. 2 , there are microlenses 12 a , 12 b , and 12 c as specific examples of the microlenses 12 .
  • the microlens 12 a includes a lens part 12 aa and a raised part 12 ab .
  • the raised part 12 ab raises the lens part 12 aa from a reference surface. Note that this reference surface is the main surface on the emission side of the plate 11 .
  • a convex part maximum height of the microlens 12 a is a sum of the lens height, which is a height of the lens part 12 aa , and a height of the raise, which is a height of the raised part 12 ab .
  • the heights of the raise of the respective microlenses 12 have a distribution within a certain range.
  • the convex part maximum heights of the respective microlenses 12 are distributed within a certain range to thereby generate the phase difference. This phase difference contributes to reduce luminance and color unevenness that occurs due to diffraction.
  • the distribution of the heights of the raise of the microlenses 12 may be determined as follows. A maximum height difference ⁇ H of the convex part maximum heights of the respective microlenses is set. Then, the heights of the raised parts may be arbitrarily distributed within the range of the maximum height difference ⁇ H such as in a uniformly random distribution, a pseudo random distribution, or the like.
  • a microlens 12 b has the greatest convex part maximum height within the certain range and the microlens 12 c has the smallest convex part maximum height within the certain range.
  • a lens part 12 ba of the microlens 12 b and a lens part 12 ca of the microlens 12 c have substantially the same cross-sectional profile.
  • the lens parts 12 ba and 12 ca have the same length in convex directions of the lens parts.
  • a difference in the heights of a raised part 12 bb and a raised part 12 cb is the maximum height difference ⁇ H.
  • Equation 1 A phase difference ⁇ P corresponding to the maximum height difference ⁇ H [ ⁇ m] of the convex part maximum heights of the respective microlenses is expressed by the following Equation 1.
  • Equation 1 A phase difference ⁇ P corresponding to the maximum height difference ⁇ H [ ⁇ m] of the convex part maximum heights of the respective microlenses is expressed by the following Equation 1.
  • Equation 1 A phase difference ⁇ P corresponding to the maximum height difference ⁇ H [ ⁇ m] of the convex part maximum heights of the respective microlenses is expressed by the following Equation 1.
  • Equation 1 A phase difference ⁇ P corresponding to the maximum height difference ⁇ H [ ⁇ m] of the convex part maximum heights of the respective microlenses is expressed by the following Equation 1.
  • the phase difference ⁇ P is preferably 0.2 or greater, and is more preferably 0.5 or greater in terms of reducing luminance and color unevenness.
  • the mat plate 20 includes a plate body 21 and a micro contoured pattern 22 .
  • the micro contoured pattern 22 is provided on a main surface on the incident side of the plate body 21 .
  • the incident side main surface of the plate body 21 provided with the micro contoured pattern 22 functions as a mat surface of the mat plate 20 .
  • each of the diffuser plates has a unique top width (described later) defined in a distribution curve of diffused light intensity.
  • the diffused light intensity is, for example, intensity with respect to a viewing angle of a transmission image of the light transmitted through the diffuser plate.
  • the top width of the mat plate 20 be selected so that the top width of the composite diffuser plate 100 will become within 1.200 times the top width of the random microlens array 10 .
  • the top width of the composite diffuser plate 100 is preferably within 1.200 times the top width of the random microlens array 10 .
  • FIG. 3 is a graph showing an example of an intensity distribution with respect to the viewing angle.
  • FIG. 4 is a graph showing a distribution obtained by performing moving average processing on the example of the intensity distribution with respect to the viewing angle.
  • FIG. 5 is a graph showing a distribution obtained by taking second derivatives of the intensity distribution with respect to the viewing angle, which has been subjected to the moving averaging processing.
  • the diffuser plate is irradiated with a He—Ne laser beam.
  • a transmission image of the He—Ne laser beam is projected onto a frosted glass.
  • This transmission image is photographed by a CCD (Charge-Coupled Device) camera.
  • luminance information is generated from the transmission image.
  • FIG. 3 the intensity distribution with respect to the viewing angle is obtained from the generated luminance information.
  • FIG. 4 moving averaging processing is performed on the obtained intensity distribution with respect to the viewing angle.
  • the distribution curve of the intensity is smoothed.
  • second derivatives processing is performed on the smoothed distribution curve.
  • the inflection points in the distribution curve that has been subjected to the second derivatives processing are obtained.
  • the top width corresponds to a width of the top hat-shaped part in the distribution curve of the intensity with respect to the viewing angle shown in FIG. 4 . Further, the top width is a width between angles of the first inflection points toward 0° from maximum values of absolute values of the viewing angle.
  • the top hat-shaped part includes, for example, one end part, an ascending part, a central part, a descending part, and another end part.
  • the one end part, the ascending part, the central part, a descending part, and the other end part are contiguous with one another in order toward a direction in which the viewing angle increases.
  • the central part is higher than the one end part and the other end part.
  • the ascending part is inclined so as to rise toward the direction in which the viewing angle increases.
  • the descending part is inclined so as to fall toward the direction in which the viewing angle increases.
  • the ascending and descending parts each have the inflection point.
  • the top width may be a width between these inflection points.
  • the top width corresponds to a width between a first inflection point P 1 and a second inflection point P 2 .
  • the first inflection point P 1 in this example is at an angle of a first inflection point toward 0° from about 20°, which is a positive maximum value of the absolute value of the viewing angle. That is, the first inflection point P 1 is at about 11°.
  • the second inflection point P 2 in this example is at an angle of a first inflection point toward 0° from about ⁇ 20°, which is a negative maximum value of the absolute value of the viewing angle. That is, the second inflection point P 2 is at about ⁇ 9°.
  • the top width is a width between about ⁇ 9° and about 11°, i.e., about 20°.
  • FIG. 6 is a graph showing a rate of change in the top width with respect to the viewing angle of the emission side mat plate.
  • FIGS. 7 and 9 are photographs showing examples of a transmission image of the composite diffuser plate according to the first embodiment.
  • FIGS. 8 and 10 are graphs showing intensity with respect to the viewing angle of the example of the transmission image of the composite diffuser plate according to the first embodiment.
  • FIG. 17 is a photograph showing an example of a transmission image of a single diffuser plate.
  • FIG. 18 is a graph showing intensity with respect to the viewing angle of the example of the transmission image of the single diffuser plate.
  • Examples 1 to 8 are related to a composite diffuser plate having the same configuration as that of the composite diffuser plate 100 (see FIG. 1 ).
  • Comparative Examples 1 and 2 are related to a single diffuser plate composed of one microlens array having the same configuration as that of the random microlens array 10 (see FIG. 1 ).
  • Example 1 Incident side microlens Emission side mat plate array diffusion angle diffusion angle [°] [°]
  • Example 1 10 0
  • Example 2 10 2
  • Example 3 10 5
  • Example 4 10
  • Example 5 22
  • Example 6 22
  • Example 7 22
  • Example 8 22
  • Comparative Example 1 10 — Comparative Example 2 22 —
  • the rate of change in the top width of the composite diffuser plate with respect to the single diffuser plate having a fixed diffusion angle of the incident side microlens array was calculated.
  • FIG. 6 shows a result of the calculated changes of rate.
  • the diffusion angle of the diffuser plate is a full width display of a half maximum of central illuminance of the diffused light which was incident on and diffused by the diffuser plate. More specifically, in the case where the diffusion angle of the incident side microlens array was 10°, i.e., the rates of change in the top width of Examples 1 to 4 were, values obtained by dividing the top widths of respective Examples 1 to 4 by the top width of Comparative Example 1.
  • FIGS. 7 and 8 show a transmission image of Example 3 and the intensity with respect to the viewing angle thereof, respectively.
  • FIGS. 9 and 10 show a transmission image of Example 4 and the intensity with respect to the viewing angle thereof, respectively.
  • FIGS. 17 and 18 show a transmission image of Comparative Example 1 and the intensity with respect to the viewing angle thereof, respectively.
  • the rate of change in the top width was slightly less than 1.200.
  • the transmission image of Example 3 was slightly larger and had smaller luminance unevenness than the transmission image of Comparative Example 1 (see FIGS. 17 and 18 ). That is, the degree of spreading of the transmission image was not very large. In addition, it was confirmed that luminance unevenness was inhibited. To be more specific, no intensity fluctuation was observed at the center of the top hat-shaped distribution curve.
  • Example 4 In the case where the diffusion angle of the emission side mat plate was 10°, i.e., in Example 4, the rate of change in the top width exceeded 1.30. As shown in FIGS. 9 and 10 , the transmission image of Example 1 was larger and had smaller luminance unevenness than the transmission image of Comparative Example 1 (see FIGS. 17 and 18 ). That is, the degree of spreading of the transmission image was large. In addition, it was confirmed that luminance unevenness was made smaller. To be more specific, no intensity fluctuation was observed at the center of the top hat-shaped distribution curve.
  • the luminance unevenness was made smaller while the rate of change in the top width did not change much, at about 1.00 to about 1.02.
  • the diffusion angle of the mat plate was 10°, i.e., in Example 8, the top hat property disappeared.
  • the top width could not be measured. Therefore, the rate of change in the top width could not be calculated.
  • the composite diffuser plate of the first embodiment by arranging the random microarray and the mat plate, it is possible to inhibit intensity fluctuations in the center of the top hat shape and to thereby inhibit local luminance unevenness.
  • the composite diffuser plate of the first embodiment it is possible to inhibit the rate of change in the top width and to thereby inhibit the spreading of the diffused light. Therefore, the intensity distribution curve of the diffused light can maintain the top hat shape in a favorable manner.
  • a diffuser plate that diffuses light so as to have a top hat-shaped intensity distribution curve is preferably applied to applications that are required to illuminate only a limited area.
  • the applications are, for example, an application where the driver's field of view needs to be illuminated such as a head-up display. It is particularly preferable to apply the composite diffuser plate according to the first embodiment to such an application. This is because the composite diffuser plate according to the first embodiment diffuses light so as to have a top hat-shaped intensity distribution curve and corrects luminance unevenness.
  • a composite diffuser plate including a uniform microlens array and a mat plate 20 .
  • lens heights and the heights of raise are uniform.
  • luminance unevenness strongly occurs due to diffraction and interference in the microlenses included in the uniform microlens array. This luminance unevenness cannot be sufficiently corrected by the mat plate 20 alone.
  • a method for increasing the diffusion angle of the mat surface of the mat plate 20 may be employed. However, in a case where this method is employed, diffusion properties as a composite diffuser plate change. Thus, the desired diffusion properties cannot be achieved.
  • the diffuser plate 100 can achieve the desired diffusion properties while inhibiting luminance unevenness that occurs due to diffraction and interference.
  • the composite diffuser plate 100 can further correct the remaining luminance unevenness by using the mat plate 20 .
  • a lens shape to be a reference is designed according to optical properties of a material forming the composite diffuser plate and a desired diffusion angle distribution.
  • a shape of the main surface of the microlens may be spherical or aspherical.
  • the optical design can be carried out using a ray tracing method or the like. It is preferable that microlenses each having a regular hexagonal bottom surface be arranged in a triangular lattice pattern on a plate. This is because the microlenses can be closest packed on the plate in this way. In order to give anisotropy to the diffusion angle properties, an aspect ratio of the microlenses may be arbitrarily set.
  • the bottom surface shape of the microlens examples include, besides a hexagon, a quadrangle and the like.
  • the microlenses may be arranged in a square lattice pattern on the plate.
  • the phase difference ⁇ P between the microlenses is set. More specifically, the phase difference ⁇ P can be obtained by using the above-described Equation 1.
  • Equation 1 the refractive index n of the material forming the microlens 12 , the wavelength ⁇ of the light source, and the maximum height difference ⁇ H of the convex part maximum height of the microlens 12 are used. In this manner, exposure data of the microlens array in which a plurality of microlenses are arranged in a desired area is generated. Such a plurality of microlenses have substantially the same lens curvature but different heights of the raise from one another.
  • a photoresist is applied to a substrate.
  • the applied photoresist is irradiated with a laser beam that is being scanned.
  • the irradiated photoresist is exposed based on the exposure data (exposure step S 1 ).
  • a wavelength of the laser beam to be used here is not particularly limited and is selected according to the type of the photoresist used.
  • the wavelength of the laser beam may be, for example, 351 nm, 364 nm, 458 nm, 488 nm (oscillation wavelengths of an Ar
  • the exposed photoresist is developed to form a photoresist master (developing step S 2 ).
  • An example of the developing method includes a method in which the exposed photoresist is immersed in an alkaline developer.
  • the alkaline developer include tetramethylammonium hydroxide (TMAH) and the like.
  • TMAH tetramethylammonium hydroxide
  • the developing step a part of the photoresist is removed from the substrate according to an amount of the exposure.
  • the photoresist remaining on the substrate has a contoured shape based on the designed microlens array.
  • a plate-shaped stamper made of nickel is formed on the surface of the photoresist of the photoresist master (electroforming step S 3 ).
  • the contoured shape of the photoresist is transferred to the surface of the stamper.
  • the stamper is released from the photoresist master to be used.
  • hot press molding is performed by pressing with the stamper (molding step S 4 ).
  • the molding step S 4 as the molding method, injection molding, imprint molding using an ultraviolet curable resin, or the like can be used instead of the hot press molding.
  • FIG. 11 is a side view of the composite diffuser plate according to the second embodiment.
  • the composite diffuser plate according to the second embodiment has the same configuration as that of the composite diffuser plate according to the first embodiment except for the following point.
  • a uniform micro random array is used in place of the mat plate 20 of the composite diffuser plate according to the first embodiment. While the different configuration will be described below, the same configuration will not be described.
  • the composite diffuser plate 200 includes a uniform microlens array 30 disposed on the emission side of the random microlens array 10 .
  • the uniform microlens array 30 includes a plurality of microlenses 32 .
  • the plurality of microlenses 32 are provided on a main surface on an incident side of a plate 31 .
  • the plurality of microlenses 32 are optically designed so that there is almost no phase difference, that is, substantially zero phase difference, therebetween.
  • the incident light passes through the random microlens array 10 and the uniform microlens array 30 in this order.
  • the composite diffuser plate 200 can be used as a transmissive screen.
  • the diffusing effect of the random microlens array 10 and the diffusing effect of the uniform microlens array 30 overlap, so that luminance unevenness caused by diffraction and interference can be inhibited.
  • the composite diffuser plate of the second embodiment it is possible to more reliably inhibit luminance unevenness from occurring locally. Additionally, there is no need to position the diffuser plates with high accuracy.
  • FIG. 12 is a side view of the composite diffuser plate according to the third embodiment.
  • the composite diffuser plate according to the third embodiment has the same configuration as that of the composite diffuser plate according to the first embodiment except for the following point.
  • the composite diffuser plate according to the third embodiment includes a reflection plate and has a different orientation of the microlens array from that of the microlens array of the first embodiment.
  • the random microlens array 10 includes a plate 11 and microlenses 12 arranged on a main surface of the plate 11 .
  • the random microlens array 10 is installed so that the microlenses 12 face the incident side.
  • the reflection plate 320 includes a plate body 21 , a micro contoured pattern 22 , and a mirror 323 .
  • the micro contoured pattern 22 is disposed on the main surface of the plate body 21 .
  • the mirror 323 is disposed on a main surface opposite to the main surface on which the micro contoured pattern 22 is disposed.
  • the reflection plate 320 is installed so that the micro contoured pattern 22 faces the incident side.
  • Example 2-1 is related to a composite diffuser plate having the same configuration as that of the composite diffuser plate 100 (see FIG. 1 ).
  • Example 2-2 is related to a composite diffuser plate having the same configuration as that of the composite diffuser plate 200 (see FIG. 11 ).
  • a random microlens array including microlenses each having a rectangular bottom surface was used as a random microlens array of each of Examples 2-1 and 2-2.
  • a plurality of microlenses were arranged at a pitch Px of 20 ⁇ m in an X direction and a pitch Py of 37 ⁇ m in a Y direction.
  • a lens radius of curvature was 58.5 ⁇ m.
  • the refractive index n of a material forming the microlenses 12 was set to 1.5, the wavelength ⁇ was set to 750 ⁇ m, and the phase difference ⁇ P was set to 1 wavelength. Then, by using the above-described Equation 1, the maximum height difference (raised height) ⁇ H of the convex part maximum height of the lenses was set to 1.5 ⁇ m.
  • the exposure step S 1 , the developing step S 2 , the first electroforming step S 3 , and the second electroforming step S 3 were performed to thereby obtain a stamper.
  • a microlens array composed of concave lenses was formed on this stamper.
  • the molding step S 4 was performed to obtain a random microlens array.
  • Example 2-1 the distance between the random microlens array and the mat plate was 1 mm. This mat plate had a diffusion angle of 5°.
  • Example 2-2 the distance between the random microlens array and the uniform microlens array was 1 mm.
  • This uniform microlens array includes a plurality of microlenses each having a rectangular bottom surface.
  • the plurality of microlenses were arranged at a pitch Px of 20 ⁇ m in the X direction and a pitch Py of 37 ⁇ m in the Y direction.
  • the lens radius of curvature was 58.5 ⁇ m.
  • Comparative Example 2-1 is related to a single diffuser plate composed of a random microlens array having the same configuration as that of the random microlens array used in Example 2-1 and Example 2-2.
  • Comparative Example 2-2 is related to a composite diffuser plate formed by arranging two uniform microlens arrays.
  • the two uniform microlens arrays have the same configurations as that of the uniform microlens array 30 (see FIG. 11 ).
  • the two uniform microlens arrays are arranged without the angles being aligned with vertexes of the microlenses.
  • Example 2-1, Example 2-2, Comparative Example 2-1, and Comparative Example 2-2 were irradiated with a He—Ne laser beam.
  • the transmission images of the He—Ne laser beam were photographed.
  • the intensity with respect to the viewing angle was measured.
  • FIGS. 13 and 14 show a transmission image of Example 2-1 and the intensity with respect to the viewing angle thereof, respectively.
  • FIGS. 15 and 16 show a transmission image of Example 2-2 and the intensity with respect to the viewing angle thereof, respectively.
  • FIGS. 19 and 20 show a transmission image of Comparative Example 2-1 and the intensity with respect to the viewing angle thereof, respectively.
  • FIGS. 21 and 22 show a transmission image of Comparative Example 2-2 and the intensity with respect to the viewing angle thereof, respectively.
  • the luminance is greatly fluctuated in a central part, specifically, the viewing angles between ⁇ 5° and 5°. That is, luminance is locally uneven. It is presumed that this luminance unevenness is caused by the diffraction phenomenon and the interference phenomenon and could not have been sufficiently corrected by the raised height random microlens array alone.
  • the transmission image of Example 2-1 has smaller luminance unevenness at the central part than the transmission image of Comparative Example 2-1 (see FIGS. 19 and 20 ). This is presumed to be because the mat plate having an effect of diffusing light inhibited the luminance unevenness from occurring locally.
  • the transmission image of Example 2-2 has smaller luminance unevenness at the central part than the transmission image of Comparative Example 2-1 (see FIGS. 19 and 20 ). This is presumed to be because the uniform microlens array having an effect of diffusing light inhibited the luminance unevenness from occurring locally.
  • the transmission image of Comparative Example 2-2 has large luminance unevenness entirely than the transmission image of Comparative Example 2-1 (see FIGS. 19 and 20 ).
  • Comparative Example 2-2 the two uniform microlens arrays were arranged without aligning the angles with respect to the vertexes of the microlenses. The large luminance unevenness is presumed to be because of this.
  • Patent Literature 2 discloses a single diffuser plate.
  • a rough surface formed of a fine contoured structure is provided on a rear side of a microlens array.
  • This microlens array is disposed in such a way that the rough surface will be on a light source side of a liquid crystal display.
  • the composite diffuser plates according to the above-described embodiments can further inhibit luminance unevenness that occurs due to diffraction.
  • Patent Literature 3 discloses a composite diffuser plate. This composite diffuser plate aims to reduce luminance unevenness by shifting the angles of the vertexes of the microlenses in the microlens array from the angles of the vertexes of the microlenses in another microlens array by a certain angle.
  • Patent Literature 4 discloses a composite diffuser plate. This composite diffuser plate aims to reduce luminance unevenness by reducing lens intervals of a microlens array on an incident side to an integral multiple of those of a microlens array on an emission side.
  • Patent Literature 5 and Non Patent Literature 1 disclose composite diffuser plates. Each of these composite diffuser plates aims to reduce luminance unevenness by arranging two microlens arrays at a focal length distance.
  • the composite diffuser plates according to the above-described embodiments can inhibit luminance unevenness from occurring locally without limiting the method of arranging a plurality of diffuser plates in particular.
  • the alignment tolerances of the microlens arrays are very tight. Specifically, ⁇ 0.5 ⁇ m for the distance between the two microlens arrays, and ⁇ 3 mdeg for the vertexes of the microlenses of the two microlens arrays. Therefore, it is extremely difficult to position the microlens arrays in a case where they are mounted on a product such as a head-up display. Additionally, members may be deformed or positions to which the microlens arrays are attached may vary due to changes in the operating temperature and humidity environment of the head-up display. Accordingly, the alignment may be outside of the tolerances to thereby possibly generate luminance unevenness.
  • the random microlens array is disposed on the incident side and the mat plate is disposed on the emission side.
  • the mat plate may be disposed on the incident side and the random microlens array may be disposed on the emission side.
  • the random microlens array includes the microlenses on the main surface on the emission side.
  • the microlenses may be disposed on the main surface on the incident side.
  • the random microlens array is disposed on the incident side, and the uniform microlens array is disposed on the emission side.
  • the uniform microlens array may be disposed on the incident side, and the random microlens array may be disposed on the emission side.
  • the random microlens array includes the microlenses on the main surface on the emission side.
  • the microlenses may be provided on the main surface on the incident side.
  • the uniform microlens array includes the microlenses on the main surface on the emission side.
  • the microlenses may be provided on the main surface on the incident side.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Optical Elements Other Than Lenses (AREA)
  • Liquid Crystal (AREA)
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JPWO2016163125A1 (ja) 2018-02-01
EP3282293A1 (en) 2018-02-14
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CN107430220B (zh) 2021-03-09
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KR102026005B1 (ko) 2019-09-26
KR20170129926A (ko) 2017-11-27

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